Stress-strain state analysis of the thin-walled connector housings at their manufacture by the sheet metal plastic deformation

The paper analyzes advantages and disadvantages of the existing options in designing connector housings for the on-board cable systems of launch vehicles and spacecraft. It proposes a new housing design and manufacturing technology combining advantages of the known technical solutions and eliminating their disadvantages. The design is based on a seamless thin-walled universal casing connected to the pipe with the conductive glue or by the magnetic pulse stamping. By changing the flanged hole’s angular position on the casing, it becomes possible to manufacture housings for connecting cables at different angles achieving the cable system compact laying. Technology for manufacturing a seamless casing was substantiated based on introduction of the thin-sheet metal plastic deformation. Using the numerical simulation method in the Deform software package made it possible to analyze the stress-strain state of an axisymmetric casing during drawing in a tool die. It is shown that it is advisable to manufacture the casing by rotary drawing from a workpiece with intermediate configuration previously drawn in a die. Geometric parameters of the intermediate workpiece were justified. Numerical calculations established that the intermediate workpiece for the casing rotary drawing could be drawn in a tool die in a single operation. The proposed casing design and manufacturing technology ensure high reliability of the cable connections due to the missing longitudinal joint in the connector body. Research results analysis shows that geometric parameters and mass characteristics of the seamless casing fully comply with the requirements for the products of this type.

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